A graphene-reinforced copper conductor high-conductivity smart shielded cable

Abstract

This utility model discloses a graphene-reinforced copper conductor high-conductivity intelligent shielded cable, comprising a graphene super copper conductor, the graphene super copper conductor being extruded with a fluorinated ethylene propylene copolymer insulation layer to form the core; multiple grooves are uniformly formed on the outer surface of the fluorinated ethylene propylene copolymer insulation layer, among which three grooves spaced 120° apart contain temperature-sensing optical fibers; the fluorinated ethylene propylene copolymer insulation layer is covered with a PET polyester tape, the PET polyester tape is covered with a first double-sided insulating water-blocking tape, the first double-sided insulating water-blocking tape is sequentially covered with a first shielding layer and a second shielding layer, the second shielding layer is covered with a second double-sided insulating water-blocking tape, and the second double-sided insulating water-blocking tape is extruded with a polyphenylene sulfide outer sheath; by optimizing the cable structure and material selection, the cable's conductivity, mechanical properties, temperature resistance, and electromagnetic shielding performance are improved, while the cable's operating temperature rise can be monitored in real time to meet the high requirements of the cable's operating environment.

Description

Technical Field

[0001] This utility model relates to the field of power cables, specifically to a graphene-reinforced copper conductor high-conductivity smart shielded cable. Background Technology

[0002] As a core carrier for power transmission and information delivery, cables are widely used in key areas such as power transmission, communication networks, and industrial automation. With the rapid development of technology, especially the rise of emerging fields such as 5G / 6G communication, the Internet of Things, artificial intelligence, new energy power systems, and high-speed rail, unprecedentedly stringent requirements have been placed on cable performance. These requirements are mainly reflected in higher conductivity, superior mechanical properties and temperature resistance, stronger electromagnetic shielding effectiveness, and intelligent monitoring needs. While traditional pure copper conductors have excellent conductivity, their conductivity is nearing its theoretical limit, leaving very limited room for further improvement. At high temperatures, conductor resistance increases by more than 20%, and high-current scenarios easily cause insulation heating and aging. Furthermore, the strength of traditional pure copper conductors decreases significantly at high temperatures, and their creep resistance is insufficient. Long-term use may lead to conductor deformation, increased contact resistance, and even safety hazards. Traditional cables have limited shielding methods, insufficient shielding effectiveness, and suffer from poor flexibility, easy oxidation, and poor grounding. In addition, traditional cables are "dumb" devices; their internal operating temperature rise is difficult to monitor in real time, making fault warning and predictive maintenance impossible.

[0003] For the reasons mentioned above, it is necessary to develop a graphene-reinforced copper conductor high-conductivity smart shielded cable. Utility Model Content

[0004] To address the problems existing in the prior art, this utility model provides a graphene-reinforced copper conductor high-conductivity smart shielded cable. This cable has excellent conductivity, mechanical properties, temperature resistance, and electromagnetic shielding properties, and can monitor the temperature rise status of the cable in real time.

[0005] To achieve the above objectives, this utility model provides a graphene-reinforced copper conductor high-conductivity intelligent shielded cable, comprising a graphene super copper conductor, wherein the graphene super copper conductor is externally extruded with a fluorinated ethylene propylene copolymer insulation layer to form the core; the outer surface of the fluorinated ethylene propylene copolymer insulation layer is uniformly provided with multiple grooves, wherein three grooves spaced 120° apart are provided with temperature-sensing optical fibers; the fluorinated ethylene propylene copolymer insulation layer is externally covered with PET polyester tape, the PET polyester tape is externally covered with a first double-sided insulating water-blocking tape, the first double-sided insulating water-blocking tape is sequentially covered with a first shielding layer and a second shielding layer, the second shielding layer is externally covered with a second double-sided insulating water-blocking tape, and the second double-sided insulating water-blocking tape is externally extruded with a polyphenylene sulfide outer sheath.

[0006] Preferably, the graphene super copper conductor is composed of a central circular graphene super copper wire and multiple shaped graphene super copper wires twisted together in a “6+12+18+24” arrangement around the central circular graphene super copper wire.

[0007] Preferably, the PET polyester tape is wrapped in a double-layer overlapping manner, with each layer having an overlap rate of not less than 15%.

[0008] Preferably, the first double-sided insulating water-blocking tape is wrapped in two overlapping layers, with each layer having an overlap rate of not less than 15%.

[0009] Preferably, the first shielding layer is made of double-layer tin-plated soft copper strips with gaps, the middle part of the outer copper strip is above the gap of the inner copper strip, and the overlap rate between the inner and outer copper strips is not less than 15%.

[0010] Preferably, the second shielding layer is made of a mixture of tin-plated copper wire and semi-conductive aramid wire, with a weaving density of not less than 80%.

[0011] Preferably, the second double-sided insulating water-blocking tape is wrapped in two overlapping layers, with each layer having an overlap rate of not less than 15%.

[0012] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0013] 1. Compared with the conventional tightly compressed circular copper conductor structure, the circular copper conductor structure of this utility model with twisted wire has the following advantages: the conductor surface is smoother and burr-free, improving the safety and reliability of the cable; the gap between individual wires is smaller, the fill factor reaches more than 0.96, the conductor structure is more stable, the contact resistance of individual wires is small, and the increase in resistance due to metal lattice deformation during stranding is small. Therefore, while meeting the requirement that the DC resistance of the conductor at 20℃ meets the GB / T 3956 standard, the required effective cross-sectional area of ​​the conductor is smaller, the outer diameter of the conductor is also smaller, the copper conductor material consumption is reduced, effectively reducing the cable manufacturing cost. Furthermore, the reduction in the outer diameter of the conductor leads to a reduction in the material consumption required for subsequent processes, which can further reduce the cable manufacturing cost. Conversely, with the same effective cross-sectional area, the current carrying capacity of the cable is higher.

[0014] The copper wires used in the conductors are all drawn from graphene super copper. Compared with ordinary pure copper, graphene super copper has advantages such as high conductivity (conductivity can reach over 110% IACS), high thermal conductivity (thermal conductivity can reach 440W / m·K), high strength, wear resistance, oxidation resistance, and a low temperature coefficient of resistance. High conductivity effectively improves the current carrying capacity of the cable. Conversely, for the same current carrying capacity, the effective cross-sectional area of ​​the graphene super copper conductor can be reduced, lowering manufacturing costs. High thermal conductivity can improve the heat dissipation of the cable, further improving its current carrying capacity. High strength can improve the conductor's creep resistance, exhibiting higher stability in high-temperature environments, reducing the possibility of conductor deformation during long-term cable use, and improving the safety and reliability of the cable. Wear resistance and oxidation resistance can improve the conductor's wear resistance, oxidation resistance, and corrosion resistance, also improving the safety and reliability of the cable. A low temperature coefficient of resistance means that the conductor resistance does not increase significantly with increasing temperature, which also means that the cable has a higher current carrying capacity when operating under the highest permissible temperature conditions.

[0015] 2. The fluorinated ethylene propylene copolymer insulation layer of this utility model has excellent electrical insulation properties, high and low temperature resistance (long-term allowable operating temperature range -85℃ to +200℃), chemical stability and mechanical properties, effectively improving the high temperature resistance and corrosion resistance of the cable. The maximum allowable operating temperature of 200℃ is much higher than the 90℃ of conventional cross-linked polyethylene insulated cables. This means that the current carrying capacity of this utility model is much higher than that of conventional cables. At the same time, the material is non-flammable and can prevent the spread of flames, thus improving the flame retardant performance of the cable.

[0016] 3. The present invention provides multiple micro-grooves evenly arranged on the insulation layer as heat dissipation grooves for the cable. Some of the heat generated by the cable during operation can be diffused outward through the heat dissipation grooves, thereby improving the heat dissipation of the cable and further enhancing its current carrying capacity.

[0017] 4. This utility model is equipped with a temperature-measuring optical fiber, which can monitor the temperature changes of the cable and its surrounding environment in real time, avoid cable overload and overheating, ensure cable operation safety, detect local overheating in real time, prevent fire caused by cable faults, and in the event of a fire, detect the fire in the cable channel in real time, accurately locate the fire, and realize predictive operation and maintenance, fault early warning and intelligent fire rescue.

[0018] 5. The first double-sided insulating water-blocking tape and the second double-sided insulating water-blocking tape are respectively wrapped around the inner and outer sides of the shielding layer, so that the shielding layer has a longitudinal water-blocking effect and prevents water vapor from penetrating and corroding the shielding layer.

[0019] 6. The double-layer shielding structure of this utility model effectively enhances the shielding performance of the cable. The first shielding layer adopts a double-layer tin-plated soft copper strip with gap wrapping. The tin-plated copper strip can enhance the anti-oxidation and corrosion resistance of the shielding layer, and the double-layer gap wrapping can enhance the bending performance and avoid excessive bending of the copper strip causing wrinkles and breakage. The second shielding layer adopts a mixed weaving of tin-plated copper wire and aramid fiber. The tin-plated copper wire can also enhance the anti-oxidation and corrosion resistance of the shielding layer. The semi-conductive aramid fiber has excellent properties such as ultra-high strength, high modulus, high temperature resistance, acid and alkali resistance, and light weight. Its strength is 5 to 6 times that of steel wire, its modulus is 2 to 3 times that of steel wire, its toughness is 2 times that of steel wire, and its weight is only about 1 / 5 of that of steel wire. It does not decompose or melt at high temperature. It not only has good anti-aging properties, but also has a long service life. Its function can further improve the tensile and torsional resistance of the entire shielding layer.

[0020] 7. This utility model uses a polyphenylene sulfide outer sheath, which has advantages such as high mechanical strength, high temperature resistance (can be used in the temperature range of 180~220℃), chemical corrosion resistance, flame retardancy, good thermal stability, and excellent electrical performance. This not only ensures the electrical insulation and temperature resistance performance of the cable, but also gives the cable a certain flame retardant property, making it suitable for laying in harsh environments, broadening the application range of the cable, and extending the service life of the cable. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of this utility model. Detailed Implementation

[0022] The present invention will be further illustrated below with reference to the accompanying drawings and specific embodiments. It should be understood that these embodiments are only for illustrating the present invention and are not intended to limit the scope of the present invention. After reading the present invention, any modifications of the present invention in various equivalent forms by those skilled in the art will fall within the scope defined by the appended claims.

[0023] like Figure 1 As shown, this utility model provides a graphene-reinforced copper conductor high-conductivity smart shielded cable, including a core composed of a graphene super copper conductor 1 and a fluorinated ethylene propylene copolymer insulation layer 2 extruded outside the graphene super copper conductor. This insulation layer gives the core excellent electrical insulation performance, high and low temperature resistance (long-term allowable operating temperature range -85℃ to +200℃), chemical stability, and mechanical properties, effectively improving the cable's high temperature resistance, corrosion resistance, and other properties. The maximum allowable operating temperature of 200℃ is far higher than the 90℃ of conventional cross-linked polyethylene insulated cables, which means that the current carrying capacity of this utility model is far higher than that of conventional cables. At the same time, the material is non-flammable and can prevent the spread of flames, thus improving the cable's flame retardant performance.

[0024] In this example, the graphene super copper conductor 1 is composed of a central circular graphene super copper wire and multiple profiled graphene super copper wires stranded around the central circular graphene super copper wire in a "6+12+18+24" arrangement. Compared with the conventional circular wire stranded and compacted circular copper conductor structure, the advantages of the profiled stranded circular copper conductor structure include: First, the conductor surface is smoother and burr-free, improving the safety and reliability of the cable; the gap between individual wires is smaller, the fill factor reaches more than 0.96, the conductor structure is more stable, the contact resistance of individual wires is low, and the increase in resistance due to metal lattice deformation during stranding is small. Therefore, while meeting the requirement that the DC resistance of the conductor at 20℃ meets the GB / T 3956 standard, the required effective cross-sectional area of ​​the conductor is smaller, the outer diameter of the conductor is also smaller, the copper conductor material consumption is reduced, effectively reducing the cable manufacturing cost. Furthermore, the reduction in the outer diameter of the conductor leads to a reduction in the material consumption required for subsequent processes, which can further reduce the cable manufacturing cost. Conversely, with the same effective cross-sectional area, the cable current carrying capacity is higher.

[0025] Secondly, the copper wires used in the conductors are all drawn from graphene super copper. Compared with ordinary pure copper, graphene super copper has advantages such as high conductivity (conductivity can reach over 110% IACS), high thermal conductivity (thermal conductivity can reach 440W / m·K), high strength, wear resistance, oxidation resistance, and a low temperature coefficient of resistance. High conductivity effectively improves the current carrying capacity of the cable. Conversely, for the same current carrying capacity, the effective cross-sectional area of ​​the graphene super copper conductor can be reduced, lowering manufacturing costs. High thermal conductivity can improve the heat dissipation of the cable, further improving its current carrying capacity. High strength can improve the conductor's creep resistance, exhibiting higher stability in high-temperature environments, reducing the possibility of conductor deformation during long-term cable use, and improving the safety and reliability of the cable. Wear resistance and oxidation resistance can improve the conductor's wear resistance, oxidation resistance, and corrosion resistance, also improving the safety and reliability of the cable. A low temperature coefficient of resistance means that the conductor resistance does not increase significantly with increasing temperature, which also means that the cable can operate at the highest permissible temperature with a higher current carrying capacity.

[0026] Multiple grooves 21 are uniformly opened on the outer surface of the fluorinated ethylene propylene copolymer insulation layer 2. Each groove is opened along the longitudinal direction of the insulation layer and its length is consistent with the length of the insulation layer. Multiple micro grooves serve as heat dissipation grooves for the cable. Some of the heat generated by the cable during operation can be diffused outward through the heat dissipation grooves, thereby improving the heat dissipation of the cable and further improving the current carrying capacity of the cable.

[0027] In addition, temperature-measuring optical fibers 3 are installed in three grooves spaced 120° apart, which can monitor the temperature changes of the cable and its surrounding environment in real time. This can prevent the cable from overloading and overheating, ensuring the safe operation of the cable. It can also detect local overheating in real time, preventing fires caused by cable faults. In addition, in the event of a fire, it can also detect the fire in the cable channel in real time, accurately locate the fire, and realize predictive operation and maintenance, fault early warning, and intelligent fire rescue.

[0028] A double-layer overlapping PET polyester tape 4 is used to wrap the fluorinated ethylene propylene copolymer insulation layer, with each layer having an overlap rate of not less than 15%. A double-layer overlapping first double-sided insulating water-blocking tape 5 is then wrapped around the PET polyester tape, with each layer having an overlap rate of not less than 15%. A first shielding layer 6 and a second shielding layer 7 are sequentially wrapped around the first double-sided insulating water-blocking tape. A second double-layer overlapping second double-sided insulating water-blocking tape 8 is then wrapped around the second shielding layer, with each layer having an overlap rate of not less than 15%. A polyphenylene sulfide outer sheath 9 is extruded over the second double-sided insulating water-blocking tape. This design features high mechanical strength, high temperature resistance (usable in the temperature range of 180~220℃), chemical corrosion resistance, flame retardancy, good thermal stability, and excellent electrical properties. This not only ensures the electrical insulation and temperature resistance of the cable but also gives it certain flame-retardant properties, making it suitable for laying in harsh environments and broadening the cable's application range.

[0029] In this example, the first shielding layer 6 is made of double-layered tin-plated soft copper strips with gaps, the middle part of the outer copper strip is above the gap of the inner copper strip, and the overlap rate between the inner and outer copper strips is not less than 15%; the second shielding layer is made of a mixture of tin-plated copper wire and semi-conductive aramid fiber, with a weaving density of not less than 80%; the double-layer structure effectively enhances the cable shielding performance, the tin-plated copper strip can enhance the oxidation and corrosion resistance of the shielding layer, and the double-layer gap wrapping can enhance the bending performance and avoid wrinkling and breakage of the copper strip due to excessive bending; the second shielding layer is made of tin-plated copper strips. The copper wire and aramid wire are woven together. Tin-plated copper wire can also enhance the anti-oxidation and corrosion resistance of the shielding layer. Semi-conductive aramid wire has excellent properties such as ultra-high strength, high modulus, high temperature resistance, acid and alkali resistance, and light weight. Its strength is 5 to 6 times that of steel wire, its modulus is 2 to 3 times that of steel wire, its toughness is 2 times that of steel wire, and its weight is only about 1 / 5 of that of steel wire. It does not decompose or melt at high temperatures. It not only has good anti-aging properties, but also has a long lifespan. Its function can further improve the tensile and torsional resistance of the entire shielding layer.

[0030] In summary, this application aims to provide a graphene-reinforced copper conductor high-conductivity smart shielded cable. By optimizing the cable structure and material selection, it improves the cable's conductivity, mechanical properties, temperature resistance, and electromagnetic shielding performance. At the same time, it can monitor the cable's operating temperature rise in real time to meet the high requirements of the cable's operating environment.

[0031] There are many specific applications of this utility model. The above description is only a preferred embodiment of this utility model. It should be noted that for those skilled in the art, several improvements can be made without departing from the principle of this utility model, and these improvements should also be considered within the protection scope of this utility model.

Claims

1. A graphene-reinforced copper conductor high-conductivity smart shielded cable, characterized in that: The device includes a graphene super copper conductor, which is externally extruded with a fluorinated ethylene propylene copolymer insulation layer to form a wire core. Multiple grooves are uniformly formed on the outer surface of the fluorinated ethylene propylene copolymer insulation layer, with temperature-sensing optical fibers installed in three grooves spaced 120° apart. The fluorinated ethylene propylene copolymer insulation layer is covered with a PET polyester tape, which is then covered with a first double-sided insulating water-blocking tape. The first double-sided insulating water-blocking tape is subsequently covered with a first shielding layer and a second shielding layer. The second shielding layer is then covered with a second double-sided insulating water-blocking tape, which is then externally extruded with a polyphenylene sulfide outer sheath.

2. The graphene reinforced copper conductor high conductivity smart shielded cable according to claim 1, wherein: The graphene super copper conductor is composed of a central circular graphene super copper wire and multiple shaped graphene super copper wires twisted together in a "6+12+18+24" arrangement around the central circular graphene super copper wire.

3. A graphene reinforced copper conductor high conductivity smart shielded cable as claimed in claim 2, wherein: The PET polyester tape is wrapped in a double-layer overlapping manner, with each layer having an overlap rate of not less than 15%.

4. The graphene reinforced copper conductor high conductivity smart shielded cable according to claim 3, wherein: The first double-sided insulating water-blocking tape is wrapped in two overlapping layers, with each layer having an overlap rate of not less than 15%.

5. A graphene reinforced copper conductor high conductivity smart shielded cable as claimed in claim 4, wherein: The first shielding layer is made of double-layer tin-plated soft copper strips with gaps. The middle part of the outer copper strip is above the gap of the inner copper strip, and the overlap rate between the inner and outer copper strips is not less than 15%.

6. The graphene-reinforced copper conductor high-conductivity smart shielded cable according to claim 5, characterized in that: The second shielding layer is made of a mixture of tin-plated copper wire and semi-conductive aramid fiber, with a weaving density of not less than 80%.

7. A graphene reinforced copper conductor high conductivity smart shielded cable according to claim 6, characterized in that: The second double-sided insulating water-blocking tape is wrapped in double layers with an overlap rate of not less than 15% for each layer.

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